International Research Journal of Engineering and Technology (IRJET)
e-ISSN: 2395-0056
Volume: 06 Issue: 04 | Apr 2019
p-ISSN: 2395-0072
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FEA & EXPERIMENTAL ANALYSIS OF THREE POINT BENDING TEST OF
THIN WALLED CIRCULAR STRUCTURES WITH ALUMINIUM HONEYCOMB
Milind Gaikwad1, Amol Gaikwad2
1PG
Student,Mechanical Department, Dr DYPSOE,Pune-411047
2Professor at Dr DYPSOE,Pune-411047
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Abstract - Now a days, Aluminium honeycomb filled carbon
common feature of all such structures is an array of hollow
cells formed between thin vertical walls. The cells are often
columnar and hexagonal in shape. A honeycomb shaped
structure provides a material with minimal density and
relative high out-of-plane compression properties and outof-plane shear properties. Man-made honeycomb structural
materials are commonly made by layering a honeycomb
material between two thin layers that provide strength in
tension. This forms a plate-like assembly. Honeycomb
materials are widely used where flat or slightly curved
surfaces are needed and their high Specific strength is
valuable. They are widely used in the aerospace industry for
this reason, and honeycomb materials in aluminum,
fibreglass and advanced composite materials have been
featured in aircraft and rockets since the 1950s. They can
also be found in many other fields, from packaging materials
in the form of paper-based honeycomb cardboard, to
sporting goods like skies and snowboards. Man-made
honeycomb structures include sandwich-structured
composites with honeycomb cores.
fiber reinforced plastic (CFRP) thin walled square type of
beams are used as it has the high energy absorption capacity.
CFRP thin walled structures are considered exceptionally
efficient energy-absorbing components for aerospace and
automotive engineering applications. So, in this project
we will take the circular specimen which is filled with
aluminium honey comb material. The 3 D model will be drawn
with the help of CATIA software. The three point bending
experimental testing will be carried out. The analysis will be
carried out with the help of ANSYS software. The experimental
and FEA results will be compared. The result and conclusion
will be drawn & the suitable future scope will be
suggested.
Key Words: FEA, THREE POINT BENDING TEST, CFRP.
1.INTRODUCTION
It has been proven that Carbon Fibre Reinforced Plastic
(CFRP) is an effective energy-absorbing material. CFRP thinwalled structures are considered exceptionally efficient
energy-absorbing components for aerospace and automotive
engineering applications. However, the issue as to how to
decide the best possible structural configuration still
presents a challenge. Composite structures filled with
lightweight materials have also attracted considerable
interest due to their potential to enhance the energyabsorbing capability of composite structures. Moreover,
honeycomb filling has been shown to be efficient in
improving the energy absorption and specific energy
absorption of composite structures. It should be noted that
aluminum honeycomb filled CFRP thin-walled circular
beams have not been studied in depth. As such,
understanding
their mechanical behaviour
and
crashworthiness would be of critical importance to more
extensive and reliable application of such composites.
Extensive studies have been made on the crashworthiness
characteristics of composite structures with lightweight
filler. Aluminum honeycomb has attracted much attention
as a typical cellular material due to its excellent mechanical
and energy absorption property, and specific strength-toweight ratio. Honeycomb structures are natural or manmade structures that have the geometry of a honeycomb to
allow the minimization of the amount of used material to
reach minimal weight and minimal material cost. The
geometry of honeycomb structures can vary widely but the
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2. LITERATURE REVIEW
A. Literature Survey
et al [1], Experimental and numerical investigations of
steel-polymer hybrid floor panels subjected to threepoint bendingJaeho Ryua, Yong Yeal Kimb, Man Woo
Parkc, Sung-Won Yoond, Chang- Hwan Leee, Young K. Ju
A new floor system for steel buildings was developed that
can replace conventional concrete deck slab systems. The
floor system is designed with a new type of composite panel
with a polymeric material filling between the top and bottom
steel plates. Its salient features are its light weight and
simple installation that reduce structural materials and
shorten the construction period. Experiments with various
independent variables were performed to evaluate the
flexural capacity of the proposed composite panel, and a
finite element analysis was also conducted to examine the
state of the stresses generated between the steel plate and
the polymeric core. The test results showed that the
proposed panel exhibited very ductile behavior and
maintained its structural integrity even after a maximum
load. No other failure mode than the face yielding of the top
and bottom steel plates was observed. The bond strength
between the polymeric material and the steel plates was
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International Research Journal of Engineering and Technology (IRJET)
e-ISSN: 2395-0056
Volume: 06 Issue: 04 | Apr 2019
p-ISSN: 2395-0072
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confirmed to be sufficient, even without any special surface
treatment or any additional shear connectors, to maintain
the stability of the proposed panel and to resist the forces
generated at the interface between the two materials. Design
equations for predicting the flexural strength and stiffness of
the proposed panel were proposed, and its suitability was
verified. Additionally, the experimentally tested efficient
methods for field applications of the proposed panel
regarding cutting and joining were presented in this paper.
methods available to predict the response of the beams
under such load condition due to the complicated
deformation features and influencing factors. In this paper, a
detailed investigation on the three-point bending collapse of
rectangular beams is performed. Quasi-static three-point
bending tests are conducted first for thin-walled rectangular
tubes. Numerical simulations are then performed by
nonlinear finite element code LS-DYNA to investigate the
bending responses. Parametric studies are carried out for
thin-walled rectangular beams to investigate the influences
of the span, the cross-sectional geometrical configurations
and the diameter of the punch on bending responses. Results
show that the geometrical parameters have great influence
on the deformed shapes, force and moment responses of the
beams. Finally, the bending responses of rectangular beams
in experiment and simulation are compared with Kecman's
model, which is proposed for pure bending. Big deviations
are observed and hence a theoretical method basing on
Kecman's model is proposed to predict their bending
responses under three-point bending. Comparisons show
that the proposed theoretical method can well predict the
moment response of thin-walled rectangular beams under
three-point bending.
et al [2], Mathematical Simulation of Nonlinear Problem
of Three-Point Composite Sample Bending Test, I.B.
Badriev, M.V. Makarov, V.N. Paimushin
This study is devoted to numerical analysis of the
geometrically and physically nonlinear problem of threepoint bending test of laminated fiber-reinforced composite
samples with rectangular crosssection. The problem is
formulated by using relationships based on describing the
displacement vector for an arbitrary point on the beam
(Timoshenko model). For numerical solution of the problem,
the finite sums method is used. In accordance with this
method, the initial equations are reduced to integroalgebraic equations, which are then approximated by a
collocation method using Gauss nodes. Implemented
numerical enables a very accurate description of solution
having large gradients change at very short sections.
Buckling of the beam under transverse load has been
studied by altering the loading parameter.
et al [5], Thermal-stress analysis of beam loaded by 3point bending
Sapietová
This paper describes investigation of experimental thermal
stress analysis of stainless steel which was loaded by threepoint bending. Loading took place cyclically with constant
amplitude. The measurements were performed using as
contactless scanning of infrared radiation emitted during
loading from the face of specimen. The results were
evaluated according to the theory of thermos elasticity. After
evaluation of the results we get stress distribution of first
invariant on the front face of the specimen.
et al [3], Considering damages to open-holed composite
laminates modified by nanofibers under the three-point
bending test A. Gholizadeha, M. Ahmadi Najafabadia,H.
Saghafib, R. Mohammadi
Nowadays, many components are made of composite
laminates assembly by bolted or riveted joints. Thus, the
drilling of laminates is a usual machining operation in many
industries. Due to the stress concentration around the hole,
different damage modes can occur during the service. In this
study, the effect of interleaving Nylon 66 nanofibers between
glass/epoxy laminate on decreasing damage under the
three-point bending test is considered. The results showed
that applying nanofibers caused a 57% decrease in the
delaminated area. On the other hand, the Acoustic Emission
(AE) technique was used to consider the effect of Nylon 66
nano fiber on other damage modes, matrix cracking,
fiber/matrix debonding, and fiber breakage. AE signals were
analyzed with three different methods, the outcomes
showing that these damages significantly decreased.
B. Closure of the review
Literature review shows following research areas to be
addressed for improving Bending behaviour and
energyabsorption characteristics.
• Square tubes have a strong tendency to undergo tearing of
the tube corners, which is inefficient and difficult to control.
Therefore, for practical purposes, the circular tubes are
strongly recommended.
• It is suggested to further study on the design optimization
of the tube filling structures for more efficient and reliable
energy absorbing components.
et al [4], Three-point bending collapse of thin-walled
rectangular beams Zhixin Huanga, Xiong Zhang
C. Problem Statement
To investigate the Bending response and energy absorption
characteristics of the circular aluminium column with and
without honeycomb structure to reduce injury to the
passengers and damage to the vehicle.
Three-point bending collapse is an important energy
absorption mechanism of thin-walled beams subjected to
crash loads. However, currently, there are still no theoretical
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D. Objectives
consuming activity to scan hand drawn blueprints and then
expand upon digitally. Now days three-dimensional
drawings are created using CAD software to maximize
productivity and provide quicker, better product results,
allowing for the development of the tiniest details.
1. A non-linear finite element analysis of aluminium
Specimen (With and Without Honeycomb)
2. Experimental study of aluminium specimen (With and
Without Honeycomb) by using UTM
3. To validate the FEA and Experimental results.
B. Cad Models
E. Methodology
• CAD model generation (CATIA-V5)
• Finite Element Analysis (ANSYS)
• Manufacturing Stage
• Fabrication of Assembly
• Compression Testing (UTM)
Using the knowledge from literature review, we know how
the 3D CAD model is to be prepared. The conditions required
for applying various constraints will be decided based on
literature review.
➢ 3D CAD Model Generation
• Getting input data on dimensions aluminium column
• Creating 3D model in CATIA-V5
➢ Determination of boundary conditions
• Determination of different loads and boundary condition
acting on the component by studying various ref papers, and
different resources available
➢ Testing and Analysis
• Using the best suitable material for the application
referring different literatures
• Meshing the CAD model and applying the boundary
conditions
• Solve for the solution of meshed model using ANSYS
➢ Fabrication, Experimental validation and Result
• Fabrication of specimens
• Suitable experimentation (UTM)
• Validation of result by comparing with software results.
Fig.1 Aluminium Circular Structure
Fig.2 Aluminium +Carbon Fibre Circular Structure
3. DESIGN
A. Cad
The CAD or the computer aided design process is the
enrichment of the traditional manual design process by
using computer software and hardware extensively. The
whole design process becomes much faster, robust and
reliable by using computers. The output of a computer aided
design process typically is 2D drawings and/or 3D
parts/components like curves, surfaces and solids. The
output of CAD process also contains data like material
properties, dimensions, tolerance and manufacturing
process specific information. The flexibility to draft and
design in a digital sphere is provided by CAD, which were
previously done manually. The output of CAD process makes
data handling easier, safer, and quicker because these are in
digital format. Prior it was very cumbersome and time-
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CAD GENERATION DRAFTING OF HONEYCOMB
STRUCTURE
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Volume: 06 Issue: 04 | Apr 2019
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Fig.5 Aluminium circular structure Meshed Model
Fig.3 Aluminium +Carbon Fibre+Honeycomb Circular
Structure
4. ANALYSIS
We will perform the analysis on the software Ansys. As we
don’t have a specified parameter on which we will compare
the FEA results with the experimental results, we will
Consider “DISPLACEMENT’ as the specified parameter
through which we can conclude the end results.
Here in all the three models we will consider displacement as
1mm throughout.
Fig.6 Aluminium circular structure Total Deformation
Also each model is 2mm in thickness.
Fig.7 Aluminium circular structure Equivalent stress
Fig.4 Aluminium circular structure Geometric Model
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Fig.7 Aluminium circular structure Reaction Force
Fig.11 Aluminium circular + carbon fibre structure
Equivalent stress
Fig.8 Aluminium circular+Carbon Fibre structure
Geometric Model
Fig.12 Aluminium +Carbon fibre circular structure
Reaction Force
Fig.9 Aluminium circular+carbon fibre structure Meshed
Model
Fig.13 Aluminium circular + Carbon Fibre + Honeycomb
structure Geometric Model
Fig.10 Aluminium circular+carbon fibre structure Total
Deformation
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Volume: 06 Issue: 04 | Apr 2019
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Fig.16 Aluminium circular + Carbon Fibre + Honeycomb
structure Reaction Force.
Fig.14 Aluminium circular + Carbon Fibre + Honeycomb
structure Meshed Model
5. Results & Discussions
From the above analysis it is simple to conclude that the
Structure with Carbon fibre and Honeycomb has more
Reaction force than the other two models, Hence it can resist
more stress in conditions than the other two models.
Hence we can say that the strength of the Structure having
Carbon Fibre with honeycomb is highly recommended for
light weight with hight strength applications.
Fig.14 Aluminium circular + Carbon Fibre + Honeycomb
structure Total Deformation
The Experimental Validation is under process.
Here in the FEA we have taken 1mm displacement
throughout and have proceeded with the analysis part, but
for actual experimentation we will consider Force as per the
study.
Once the force is decided then after the experimentation we
can technically compare the outcome of FEA results Vs
Experimental Result.
Fig.15 Aluminium circular + Carbon Fibre + Honeycomb
structure Equivalent Stress
6. REFERENCES
[1] Experimental and numerical investigations of steelpolymer hybrid floor panels subjected to three-point
bending
Jaeho Ryua, Yong Yeal Kimb, Man Woo Parkc, Sung-Won
Yoond, Chang-Hwan Leee,
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e-ISSN: 2395-0056
Volume: 06 Issue: 04 | Apr 2019
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Young K. Ju
[2] Mathematical Simulation of Nonlinear Problem of
Three-Point Composite Sample Bending Test
I.B. Badriev, M.V. Makarov, V.N. Paimushin
[3]Considering damages to open-holed composite
laminates modified by nanofibers under the three-point
bending test
Gholizadeha, M. Ahmadi Najafabadia,H. Saghafib, R.
Mohammadi
[4]Three-point bending
rectangular beams
Zhixin Huanga, Xiong Zhang
collapse
of
thin-walled
[5]Thermal-stress analysis of beam loaded by 3-point
bending
Milan Sapietaa Vladim r De ysa Alzbeta Sapietová
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